3TJ still won't run right, carbs/electrical ?

[Hogdigerdy Dog]

Ok i'll start at the begining
I got the bike last aug and it hadn't run for about 18 months, the tank was full of crap as were the carbs, the battery was dead, the fork seals had blown all over the forks, break callipers, rotors and wheel, the screen was bust as was the top left of the fairing where the screen joins, and the clutch lever was snapped as was the left mirror (methinks it was dropped on that side )there was also a hole in the alternator casing where a bolt had been overtightened and taken the casing with it and the exhaust headers were blowing.

The bloke i got it from managed to get it going before i bought it and it sounded sweet as a nut but wouldn't rev up much past about 4 1/2 - 5 thou

job's I've done in no particular order
fixed hole in alternator casing by re-fabing with epoxy resin
exup valve has been checked and is ok
new yuasa gel battery
new clutch lever
rebuilt the top fairing + new screen
new fork seals + oil
new oil filter + oil
new break fluid + calliper strip down and rebuild (pads are ok)
carbs completely striped down and cleaned 3X, checked out the manifold boots but these seem ok, a bit old but not split
tank cleaned with metal treatment, made a couple of plates to go over the tap and fuel gauge holes to stop it leaking, put a hand full of nuts (31 to be precise) in with the acid and then shake and leave, repeat until the desired rust free tank is obtained, rinsed with hot soapy water then the hose pipe then dried with the wife's hair drier, she wasn't best pleased it kept getting to hot and cutting out, cleaned the tap right out, and re-soldered the wire back on the fuel gauge which had come off,

After all this i restarted the beast and it's still the same, sounds great till you rev it up then it's just like it's hit a rev limiter, i tried allsorts but nothings worked until i hit the kill switch one day (i normally used the key) and re-started a couple minuets later and it was perfect, revved right up there, then died back down, hit the kill again then re-started it worked for about another 20 seconds, so i thought the switch was faulty so i bought another and it's still the same so i'm stumped any help would be appreciated

cheers

PS don't know if this will help but i left the battery on the bike last night and this morning it was as flat as a pancake, it had spent 2 months in the shed and was fine 1 night on the bike and it's flat, and yes everything was turned off, in fact there's no headlight or front indicators on it nor fairing as it's still stripped down

[Taggyd]

4k revs can be a signal of something wrong with the exup i think, tried starting mine with it disconnected and it wouldnt go over 4k! try cleaning the connectors and making sure its plugged in properly, may be a broken wire or something?

[Evilchicken0]

As Taggy says try disconnecting the exup and then starting it. Make sure the exup is actually turning freely too, sometimes they sieze up. Check the cables haven't frayed where they come out of the sheathing.

Not sure about the battery but there must be a short somewhere

[Hogdigerdy Dog]

sorry should have mentioned that in the jobs done list the exup valve is ok, i even disconnected the cables to it and operated it manually and it moves freely, the bikes a hell of a lot louder with it open but it still won't rev up, there's also a bracket off the gearbox casing with nothing in it and a connector with 2 wires 1 black and 1 blue/black, i'm trying to add pics of it...http://i753.photobucket.com/albums/xx17 ... 0004-1.jpg

[Evilchicken0]

Is that from above the gearbox looking down ?

the only time I had something similar was on my 3en2 - the valve tollerances were down to zero on a couple of cyliders ... the bike as a pig to start but once warm would run and rev out.

[Hogdigerdy Dog]

yeah it is, you take off the tank and that's directly below, as you can see the rectifier is on the left, the black shiny thing at the top of the pic is the exup servo, the pots are to the right of the pic,
as i said it will rev up nicely but only for about 20 sec then it's back to no rev's, until you hit the kill (off then on) then it's ok for about 20 sec and so on, i thought it was the kill switch so i changed that and it wasn't, so i'm back to being stumped, i bloody hate electrical problems

[Strikmabill]

I'm not sure but I think that connector with the black and black/blue wires is for the fuel pump.

[Motorcycle Solutions]

check speed sensor wires also fuel pump relay or pump not working properly, the other could be the pick up coil is rusty.

[Hogdigerdy Dog]

@Strikmabill
I thought it could be for a fuel pump but i'm not sure the 3tj had a fuel pump, i can't find it in the manual or part's list but it is (according to the frame no) a very early 3tj - 89 import so the bracket could be a through-back to the earlier model or something from the jap market

[Taggyd]

they should have a fuel pump i think! my 3en1 and 3tj both have them! and it is for the fuel pump i think, if i get allowed into the shed i'll check fo you later! would still check the exup connections at the cdi end aswell!